UNDERHOOD MAINTENANCE. ENGINE OIL What does engine oil do? What does engine oil do? – Lubricates – Cools – Seals – Cleans Viscosity Viscosity Oil Types

UNDERHOOD UNDERHOOD MAINTENANCEMAINTENANCE

ENGINE OILENGINE OIL

• What does engine oil do?What does engine oil do?– LubricatesLubricates– CoolsCools– SealsSeals– CleansCleans

• Viscosity Viscosity • Oil TypesOil Types

163C

OIL FILTERSOIL FILTERS

• Cleans oilCleans oil• Paper ElementPaper Element• Inlet and Outlet Inlet and Outlet

PassagesPassages• Bypass ValveBypass Valve• Filter Filter

IdentificationIdentification

168C

OIL FILTER FLOWOIL FILTER FLOW

• Oil Filter Inlets are on outsideOil Filter Inlets are on outside• Oil Filter Outlet is in centerOil Filter Outlet is in center• Sealing surface must be correct Sealing surface must be correct • Application must be correctApplication must be correct

168C

LUBRICATION SYSTEMLUBRICATION SYSTEM

• Oil PanOil Pan• Pick Up Pick Up

ScreenScreen• Oil PumpOil Pump• Oil GalleriesOil Galleries• Pressure Pressure

Relief ValveRelief Valve

167C

COOLANTCOOLANT

• Raises Boiling PointRaises Boiling Point• Lowers Freezing PointLowers Freezing Point• Two Types of Anti-FreezeTwo Types of Anti-Freeze

– Ethylene glycolEthylene glycol– Propylene glycolPropylene glycol

• Mixture best at 50/50 Protects to -34 Mixture best at 50/50 Protects to -34 FF

• Acts as Lubricant for Water PumpActs as Lubricant for Water Pump• Remove 70% of Engine heatRemove 70% of Engine heat

170C

What color COOLANT see the What color COOLANT see the whole chart at whole chart at peak antifreezepeak antifreeze

COOLANT info COOLANT info thanks to Kevin McCartney iatnthanks to Kevin McCartney iatn

• G05 - Hybrid/low silicate/OAT/phosphate free/8.0 pH/Gold, orange,"kinda clear"or green. Chrysler (orange), Ford/ Mazda (Gold), MB (clear), Mazda (Gold), MTU marine (green).

• G48 - Hybrid/low silicate/OAT/phosphate free/8.1 pH/blue or green. BMW (blue), Volkswagon(G11) (blue), Audi (blue), Volvo (green), Saab (blue), Jaguar? (blue), Scania (blue), Man (blue).

• G34 - Carboxylate OAT/silicate free/phosphate free/8.6 pH/pink, red, etc. Porsche (Kinda red/brown/orange), Volkswagon(G12) (red), Audi (red), Saab (red),

• Dexcool - Carboxylate OAT/silicate free/phosphate free/8.6 pH/pink, red, orange,etc. very similar to G34 GM 1994 and later.

• G30 - Carboxylate OAT/silicate free/phosphate free/8.6 pH/red. High silicate light duty/phosphates/10.6 pH/green. Low silicate light duty/phosphates/1.6 pH/green. Partially formulated HD/low silicate/phosphates/10.6 pH/green. Fully formulated HD/low silicate/phosphates/10.6 pH/green.

• "OAT" stands for Organic Acid Technology.

insite - fan/eng block

RADIATORRADIATOR

• Two TypesTwo Types– CrossflowCrossflow– DownflowDownflow

• ConstructionConstruction– CopperCopper– AluminumAluminum

• HosesHoses– MoldedMolded– FlexibleFlexible

172C

WATER PUMPWATER PUMP

• InletInlet• OutletOutlet• ImpellerImpeller• HubHub• Weep HoleWeep Hole

171C

THERMOSTATTHERMOSTAT

• Engine Temp Engine Temp must be must be regulated 180 to regulated 180 to 210 degrees210 degrees

• Located in upper Located in upper passagepassage

• Engine has Engine has bypass hose for bypass hose for flow when stat is flow when stat is closedclosed

175C & 176C

Stant thermostats Cutaway

COOLING FANSCOOLING FANS

• Engine only needs air flow at Engine only needs air flow at low speeds and idlelow speeds and idle

• Types of FansTypes of Fans– MechanicalMechanical– Electric Electric – Viscous clutchViscous clutch

HOSE CLAMPSHOSE CLAMPS

• Four Types of ClampsFour Types of Clamps• Must install on hose correctly Must install on hose correctly • Do not over tightenDo not over tighten• Worm Drive easiest and does good Worm Drive easiest and does good

job of clamping hosejob of clamping hose

Crevice

Wrong Correct

Clamp

Types of hose clampsTypes of hose clamps

Twin wireSingle Wire

Constant BandWorm Drive

RADIATOR CAPRADIATOR CAP

•Cap controls Cap controls controls pressure controls pressure and vacuum and vacuum

–Each pound of Each pound of pressure can raise pressure can raise temperature 3 temperature 3 degreesdegrees

•Rating printed Rating printed on top of capon top of cap•Pressure valve is Pressure valve is connected to connected to overflow overflow reservoirreservoir

RADIATOR CAPRADIATOR CAP

COOLING SYSTEM COOLING SYSTEM MAINTENANCEMAINTENANCE


• COMMON SERVICES AND COMMON SERVICES AND REPAIRS of COOLING SYSTEMREPAIRS of COOLING SYSTEM

• Visual Inspection for external leaksVisual Inspection for external leaks• Replace radiator and heater hosesReplace radiator and heater hoses• Pressure Test Cooling System & Pressure Test Cooling System &

CapCap• Replace Thermostat and GasketReplace Thermostat and Gasket• Replace Anti-freeze and TestReplace Anti-freeze and Test• Flush Cooling SystemFlush Cooling SystemFor more information about cooling hoses go to gates web site.

http://www.gates.com/brochure.cfm?brochure=2833&location_id=3369


• Inspect and maintain coolant system hoses. Inspect and maintain coolant system hoses. • • • Look for kinks and ensure that hoses don't touch hot Look for kinks and ensure that hoses don't touch hot

or moving parts or sharp edges. or moving parts or sharp edges. • • • Oil may damage hoses; look for swollen, soft, mushy or Oil may damage hoses; look for swollen, soft, mushy or

sticky sections of hose. sticky sections of hose. • • • Check clamp connections for leakage. Tighten clamps Check clamp connections for leakage. Tighten clamps

and replace as needed. and replace as needed. • • • Physically check coolant hoses by conducting the Physically check coolant hoses by conducting the

following squeeze test.following squeeze test.• 1) Make sure the engine is cool. 1) Make sure the engine is cool.


• 2) Use your thumb and fingers to check for 2) Use your thumb and fingers to check for weakness, not the whole hand. weakness, not the whole hand.

• 3) Squeeze near the connectors. A critical form of 3) Squeeze near the connectors. A critical form of hose degradation called ECD Electrochemical hose degradation called ECD Electrochemical degradation occurs within two inches of the ends degradation occurs within two inches of the ends of the hose. of the hose.

• 4) Check for differences in the feel between the 4) Check for differences in the feel between the middle and ends of the hose. middle and ends of the hose.

• 5) If the ends feel soft, the hose should be 5) If the ends feel soft, the hose should be replaced immediately. replaced immediately.


• • • Hoses showing signs of wear or more than Hoses showing signs of wear or more than four years old should be replaced four years old should be replaced immediately. immediately.

• • • Conduct a cooling system pressure test Conduct a cooling system pressure test annually or more frequently depending on annually or more frequently depending on manufacturer recommendations and working manufacturer recommendations and working conditions.conditions.

• Many times a hose cracks from the Many times a hose cracks from the inside from ECD you cannot see it.inside from ECD you cannot see it.



Engine HeatersEngine Heaters

• Electrically operated heaters are Electrically operated heaters are often available as optional often available as optional equipment on cars and light trucks. equipment on cars and light trucks. The heater may warm coolant with a The heater may warm coolant with a heating element located in a coolant heating element located in a coolant hose or in the engine block, or the hose or in the engine block, or the heater may be located in a position heater may be located in a position that warms the engine oil. They that warms the engine oil. They help to provide easier starting in help to provide easier starting in extremely cold temperatures. extremely cold temperatures.

Types of Engine Types of Engine HeatersHeaters

ThanksNAPA

DRIVE BELTSDRIVE BELTS

PULLEYS AND BELTSPULLEYS AND BELTS

• Make sure you have the right size beltMake sure you have the right size belt• Pitch and Width must be correctPitch and Width must be correct• Tension belt in foot poundsTension belt in foot pounds• Some water pumps turn in opposite Some water pumps turn in opposite

directiondirection

Pg... 233& 234C

Belt & Pulley ProblemsBelt & Pulley Problems

Belt not aligned Pulley worn

Belt AdjustmentBelt Adjustment• Most new cars have automatic tensioners Most new cars have automatic tensioners

on them so no adjustment is needed. But on them so no adjustment is needed. But the old belts must be checked and the old belts must be checked and tightened. tightened.

Belt AdjustmentBelt Adjustment

Find the Drive Belt Picture like this one from All Data if you do not know how to adjust it.

Thanks All Data for use of the picture.

DRIVE BELTS DRIVE BELTS PROBLEMSPROBLEMS

Thanks DaycoThanks Dayco

DRIVE BELTS DRIVE BELTS PROBLEMS PROBLEMS

Thanks Dayco Thanks Dayco

DRIVE BELTSDRIVE BELTS PROBLEMS PROBLEMS

DRIVE BELTS PROBLEMSDRIVE BELTS PROBLEMS

APPEARANCE:Each side of belt appears shiny or glazed. In advanced stages, fabric becomes exposed. CAUSE:When in motion, the belt makes contact with an object in its path such as a flange or bolt. This may be caused by improper belt tension or pulley bearing size.SOLUTION:Replace belt and remove the foreign object or, if it can’t be removed, ensure that contact is voided. Check the automatic belt tensioner and ensure proper belt tension.

Thanks to Gates for picture and info


APPEARANCE: Pieces or chunks of rubber material have broken off from the belt. When chunk-out has occurred, a belt can fail at any moment.

CAUSE: Chunk-out can happen when several cracks in one area move parallel to the cord line. Heat, age and stress are the primary contributors.

SOLUTION: Replace the belt immediately.



APPEARANCE: Belt material is sheared off from the ribs and builds up in the belt grooves. CAUSE: There are a number of causes, including lack of tension, misalignment, worn pulleys or a combination of these factors. Pilling is found most frequently in diesel engines, but is not isolated to them.

SOLUTION: When pilling leads to belt noise or excess vibration, the belt should be replaced. Accessory brake pulleys should be checked for material buildup between groves. Replace if necessary.



APPEARANCE: Belt shows damage to the side with the possibility of breaks in the tensile cord or jagged edged ribs. A thumping or grinding noise may also be heard when running.

CAUSE: A foreign object—such as a small pebble—in the pulley can cause uneven wear and cut into the belt.

SOLUTION: Replace belt and inspect pulley for foreign objects or damage. Replace pulley if necessary



APPEARANCE: A belt rib begins separating from the joined strands. If left unattended, the cover will often separate, causing the belt to unravel.

CAUSE: Improper belt installation is a common cause of premature failure. One of the outer-most belt ribs is placed outside the pulley groove, causing a belt rib to run without a supporting or aligning pulley groove.

SOLUTION: The belt’s life has been severely limited and should be replaced immediately. Ensure all ribs of the replacement belt fit into the pulley grooves. Run the engine. Then, with the engine off and battery disconnected, inspect the belt for proper installation.



APPEARANCE: Small, yet visible cracks along the length of a rib or ribs.

CAUSE: With continuous exposure to high temperatures, the stress of bending around the pulley leads to cracking. Cracks begin on the ribs and grow into the cord line. As a rule, if three or more cracks appear in a three-inch section of a belt, eighty percent of the life is gone and the belt should be replaced.

SOLUTION: Replace & Check tensioner pulley and idler pulley for bearing wear. Replace if necessary.



APPEARANCE: Sidewalls of the belt may appear glazed or the edge-cord may become frayed and ribs removed. A noticeable noise may result. In severe cases, the belt can jump off the pulley.

CAUSE: Pulley misalignment can be caused by two conditions (see below). Misalignment forces the belt to kink or twist while running, causing premature wear.

SOLUTION: Replace the belt and make sure to realign the pulleys. Also check to make sure the pulleys, pulley brackets and shafts are not bent or broken.



APPEARANCE: Small pinholes are visible on the backside of the belt. Bumps may be visible and fabric around the holes can be frayed.

CAUSE: Rock, gravel or sand is wedged between the belt grooves and pulley ridges.

SOLUTION: The belt needs to be replaced to avoid tensile cord separation and possible roadside failure.


DRIVE BELTS DRIVE BELTS PROBLEMSPROBLEMS

• If You have a squeak and it If You have a squeak and it sounds like a belt try squirting sounds like a belt try squirting water on it if it goes away you water on it if it goes away you probably need a new belt.probably need a new belt.



• Make sure you Make sure you know how to know how to route the route the serpentine belt serpentine belt around the around the pulleys.pulleys.

DRIVE BELT TENSIONERDRIVE BELT TENSIONER

• ..


1. SPRING: Maintains belt tension at a constant value throughout the operating range.2. ARM: Connects spring to idler pulley while maintaining proper alignment.3. INSERT BEARING: Provides angular alignment needed for proper belt tracking.4. DAMPING ELEMENT (SPRING SUPPORT): Provides additional tensioner damping and load balancing.5. SPRING HOUSING/SPINDLE: Anchors spring. Arm pivots around the spindle.6. IDLER PULLEY: Pulley surface is grooved, flat or crowned.7. PULLEY BOLT: Allows service replacement of pulley & means for lifting arm.8. DUST SHIELD: Prevents high-pressure spray, foreign material or installation tools from damaging the bearing seal.*Note: Sometimes integrated with pulley bolt.9. FRONT PLATE: Holds tensioner together.10. THRUST WASHER: Provides thrust wear surface.

Thanks to Goodyear for the picture & info

http://www.goodyearbeltsandhose.ca/replacement/carsandlt/tensioners.html


• Make sure the tensioner is in good shape.Make sure the tensioner is in good shape.

Idler PulleysIdler Pulleys

Don’t forget the Idler Pulley. We change out Don’t forget the Idler Pulley. We change out the belt and the tensioner but forget the other the belt and the tensioner but forget the other pulley’s. Are they whining, check the nylon pulley’s. Are they whining, check the nylon ones for wear across the surface. All can wear ones for wear across the surface. All can wear but nylon ones need to be replaced more often.but nylon ones need to be replaced more often.(see picture on previous page)(see picture on previous page)

AIR INDUCTION SYSTEMAIR INDUCTION SYSTEM

• Air Filter traps abrasive Air Filter traps abrasive particlesparticles

• Must be changed regularlyMust be changed regularly• System can control inlet air System can control inlet air

temperaturetemperature• Housings usually plasticHousings usually plastic

182C

AIR INDUCTION SYSTEMAIR INDUCTION SYSTEM

• Air filter Service indicatorAir filter Service indicator• This reading shows normal indication when the

filter element is clean. (Readings vary with system design.)

• As the filter element slowly fills with dust and soot,

the indicator moves up the calibrated gauge to show the exact percentage of filter life remaining.

• Here the reading shows the filter is no longer allowing sufficient air into the engine and should be changed. http://www.cat.com/cda/layout?m=37503&x=7

Air Filter Service Air Filter Service IndicatorIndicator

FUEL SYSTEMFUEL SYSTEM

• Tank, Pump, inlet sock,sender Tank, Pump, inlet sock,sender • LinesLines• Fuel FilterFuel Filter• Fuel pressure tapFuel pressure tap

UNDERHOOD FLUIDSUNDERHOOD FLUIDS

• Power Steering FluidPower Steering Fluid• Brake FluidBrake Fluid

– ReservoirReservoir– Ratings (DOT 3,4,5)Ratings (DOT 3,4,5)– Must not use lesser ratingMust not use lesser rating

– Do not mix!Do not mix!

• Electrolyte Electrolyte – Water/acid mix in the Water/acid mix in the

batterybattery

• Window Washer FluidWindow Washer Fluid

185C - 187C

BATTERYBATTERY

• Safety is very important!Safety is very important!• Chemical ActionChemical Action

– Lead PeroxideLead Peroxide– Sponge leadSponge lead

• Battery ConstructionBattery Construction• Battery TypesBattery Types• Battery size and ratingsBattery size and ratings

187C - 195C

DUH, That’s all folks!!!

Thanks to Dayco, Cat, Auto Insite, Gates And AllDataFor the Pictures

http://www.gates.com/brochure.cfm?brochure=2837&location_id=3373

Documents

UNDERHOOD MAINTENANCE. ENGINE OIL What does engine oil do? What does engine oil do? – Lubricates – Cools – Seals – Cleans Viscosity Viscosity Oil Types